Egg carton creasing,forming and closing machine



Dec. 15, 19 70 A. E. COMSTOCK .EGG CARTON CREASING, FORMING AND CLOSINGMACHINE 5 Sheets-Sheet 1 Filed June 12. 1968 mvsw'roa Alfred E. ComsrockW Attorneys A. E. coMs'TocK 3,546,839

EGG CARTON CREASING, FORMING AND CLOSING MACHINE Dec. 15, 1970 5Sheets-Sheet 2 Filed June 12. 1968 INVENTOR. Alfred E. Comsrock SQWAttorneys Dec. 15, 1970 CQMSTOCK 3,546,839

EGG CARTON CREASING, FORMING AND CLOSING MACHINE Filed June 12, 1968 5Sheets-Sheet 3 INVENTOR Alfred E. Comstock Zr i4, W9; 4% W Dec. 15, 1970CQMSTOCK 3,546,839

EGG CARTON CREASING, FORMING AND CLOSING MACHINE Filed June 12, 1968 5Sheets-Sheet 4 //6 //a /14 us //1 r //7 a i 1/ lv a x I v //7 Z 3 F I g.5

f INVENTOR. F g. 6

Alfred E. Comsrock BY W- Attorneys Dec. 15, 1970 A. s c sm c I v f 46, 9

EGG CARTON CREASINCITORMING AND CLOSING MACHINE Filed June 12. 1968 5Sheets-Sheet 5 INVENTOR. 1 "'a 'lfr d E. Comsrock Attorneys UnitedStates Patent US. Cl. 53-78 10 Claims ABSTRACT OF THE DISCLOSURE Machinefor creasing and forming covers of molded egg cartons and closing thecovers of molded egg cartons.

BACKGROUND OF THE INVENTION In Pat. No. 3,191,844, there is disclosed anew type of molded egg carton. Such egg cartons cannot be closed withconventional carton closing machines. There is, therefore, a need for amachine which can be utilized for closing such cartons.

SUMMARY OF THE INVENTION AND OBJECTS The carton creasing, forming andcarton closing machine is for use with an egg carton of the type whichhas a bottom section and at least one hinged cover with inclined sidewalls secured to the bottom section. The machine consists of a frameworkand means is provided on the framework for engaging the bottom sectionof the carton for retianing it in a predetermined angular position.Means is provided for engaging at least one of the covers for creasingand forming the cover so that the inclination of the side walls isreduced. Means is then provided for closing the covers on the bottomsections.

In general, it is an object of the present invention to provide a cartoncreasing, forming and closing machine which is particularly adaptablefor certain types of molded egg cartons.

Another object of the invention is to provide a machine of the abovecharacter in which the carton moves while the covers are being creased,formed and closed.

Another object of the invention is to provide a machine of the abovecharacter which creases and forms the egg carton so that the carton isparticularly adaptable for use with large eggs.

Another object of the invention is to provide a machine of the abovecharacter which can crease and close the cartons very rapidly.

Another object of the invention is to provide a machine of the abovecharacter which is relatively simple to operate.

Additional objects and features of the invention will appear from thefollowing description in which the preferred embodiments are set forthin detail in conjunction with the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWING FIGS. 1A and 1B are a top plan view ofa machine incorporating the present invention.

FIGS. 2A and 2B are a side elevational view of the machine shown in FIG.1.

FIG. 3 is a cross-sectional view taken along the line 3-3 of FIG. 2A.

FIG. 4 is a cross-sectional view taken along the line 44 of FIG. 2A.

FIG. 5 is a cross-sectional view taken along the line 5-5 of FIG. 2B.

FIG. 6 is a cross-sectional view taken along the line 66 of FIG. 2B.

FIG. 7 is a top plan view of a molded egg carton of the type describedin US. Pat. No. 3,191,844 with the covers in an open position.

FIG. 8 is an end elevational view of the cartons shown in FIG. 7 withcertain portions broken away and also showing in broken lines thepositions of the covers in a closed position.

FIG. 9 is an enlarged detail view showing the manner in which thecartons are creased and formed in the carton creasing and closingmachine.

FIG. 10 is a side elevational view of a portion of another cartoncreasing, forming and closing machine.

FIG. 11 is a partial cross-sectional view of still another embodiment ofthe carton creasing, forming and closing machine.

DESCRIPTION OF THE PREFERRED EMBODIMENT The carton creasing and closingmachine 16 is used for reforming and creasing egg cartons 17 of the typeshown in FIGS. 7 and 8 and also disclosed in US Pat. 3,191,844. Asdisclosed in said Pat. 3,191,844, the carton is comprised of a bottomsection 18 having a generally rectangular configuration in plan as canbe seen in FIG. 7 with a plurality of egg receiving pockets 19. The eggreceiving pockets 19 are aligned in such a manner that there areprovided two spaced parallel rows of pockets extending longitudinally ofthe carton and six spaced parallel rows extending transversely of thecarton.

A plurality of upstanding frusto-conical posts 21 are formed as a partof the bottom section of the carton along the longitudinal centerline ofthe bottom section in between the longitudinally extending andtransversely eX- tending rows of pockets 19. Each of the posts 21 isprovided with a slot 22 of a predetermined width and depth which is inline with the longitudinal centerline of the bottom section 18 andextends in the same direction as the longitudinal centerline. As can beseen from FIG. 8, the posts 21 extend substantially above the plane ofthe lips 23 formed on the outer upper margin of the bottom section.

A pair of covers 26 are mounted on the bottom section 18. The covers 26are generally rectangular in plan as can be seen in FIG. 7. Each of thecovers is provided with spaced side walls 27 and 28 which are inclinedwith respect to a top wall 29 and generally perpendicular with respectto end walls 31. The covers 26 are formed integral with the bottomsection 19 and are hinged to the bottom section by fold lines 32 whichform hinges between the bottom section and the side walls 27 of thecovers 26. As can be seen from FIG. 8, the covers 26 are spaced parallelto each other and are both adapted to be folded inwardly so that theirinclined side walls 28 seat within the slots 22 provided in the posts21. Also note that the slots 22 have such a depth that the top walls 29of the covers are parallel to the lip 23 of the bottom section.

As explained in Pat. 3,191,844, the carton 17 can be made of anysuitable material such as paper pulp to provide a molded egg carton. Theinclined side wall provided in the covers 26 and the bottom section 18facilitate stripping the carton from the mold and also facilitatenesting of the cartons for shipment before they are filled with eggs.Other features of the carton can be ascertained from Pat. 3,191,844.

The carton creasing and closing machine is particularly adapted to beused for the creasing and closing of the cartons hereinbefore described.It consists of a framework 36 which forms a platform or table 37 lyingin a horizontal plane. As can be seen from FIGS. 1A and 1B, the platform37 is sufficiently wide so that it can accommodate two rows of cartonssimultaneously.

Means is provided for advancing the cartons on the platform or table 37and consists of a pair of conveyor belts 38 formed of a suitablematerial such as corrugated rubber. The entrance ends of the conveyorbelt 38 are mounted upon a large roller 39 carried by a shaft 41rotatably mounted in the framework 36. The upper run of the conveyorbelt 38 travels on the platform 37. The conveyor belts 38 are driven byrollers 42 mounted upon a shaft 43. The shaft 43 has a sprocket 44mounted thereon which is driven by a chain 46. The chain 46 is driven bysuitable motive means such as an electric motor (not shown) which drivesa sprocket (not shown) which drives the chain 46. A belt tighteningroller 47 mounted upon a shaft 48 is provided and engages the lower runof the conveyor belts 38. The conveyor belts 38 are adapted to besupplied with cartons 17 by suitable means such as another conveyor 49shown in broken lines in FIG. 1A.

Means is provided for holding the cartons 17 down onto the conveyorbelts 38 so that they are positively advance by the conveyor belts andconsists of hold-down fins 51. The hold-down fins 51 are L-shaped incross section as can be seen particularly in FIG. 3. The fins 51 arepositioned above the platform 37 a predetermined distance so that theirlower extremities enter the slots 22 in the cartons 17 and hold thecartons in engagement with the belts 38. Means is provided forsupporting the fins 51 in these positions and consists of threaded studs52 secured to the fins 51 by nuts 53. The studs 52 are secured to across bar 54 by additional nuts 53. The bar 54 is mounted upon spacedparallel vertical standards 56 secured to the framework 36. The forwardends of the hold-down fins 51 are mounted upon a cross member 57 byadditional studs 52 and nuts 53. The cross member 57 is supported bystandards 58 mounted on the framework 36.

The entrance ends of the hold-down fins 51 are provided with upwardlyturned rounded portions 51a. As hereinbefore explained, the fins 51 areL-shaped in crosssection and are provided with horizontally extendingportions 51b which serve to reinforce the fins 51. The fins 51 have alength which extends from near the inlet end of the conveyor belts 38 tothe point at which the cover is being folded into the slots of thecarton as hereinafter described. The fins 51 are provided at a height sothat the reinforcing portion 51b does not interfere with movement of thecovers of the cartons when they are folded inwardly by the machine. Thefins 51 are of a thickness which is only slightly less than the width ofhte slots 22 provided in the cartons.

The cartons 17 are introduced onto the conveyors 38 with their coversopen such as shown in FIG. 7. They are advanced by the conveyor beltsinto the cover creasing and forming station 59 and the covers 26 on eachside of the bottom section 18 of the cartons are engaged by guide straps61 having one end secured to the platform 37 by screws 62 and have theother end secured to the sides of guide members 63 by suitable meanssuch as welding. The guide members 63 are mounted upon posts 64 and aresecured to the platform 37 by bolts 65. Each of the guide members isprovided with a portion 63a which is secured to the post which isgenerally parallel to the platform 37 and another portion 63b which isinclined with respect to the portion 6311 at the same angle at which thecovers of the cartons are bent. Thus, for example, the portion 63b canbe inclined at an angle from the vertical of approximately 14. As thecartons are advanced by the conveyor belts 38, the covers engage theguide straps 61 which are twisted through substantially 90 to causemovement of the covers through substantially 90 so that the covers aregenerally in a vertical position as shown particularly in FIG. 3 whenthey clear the straps 61.

It will be noted that the straps 61 on opposite sides of the belt 38 arebent in opposite directions so that the covers of the cartons are liftedupwardly in opposite directions and moved towards the open end of thecarton. These guide straps 61 are formed of any suitable material suchas stainless steel.

Means is provided for reforming and creasing the covers of the cartonsas they are advanced through the machine and consists of a roller 71 foreach of the covers of the cartons secured to a shaft 72 set screws 73.The shaft 72 is rotatably mounted in bearings 74 mounted upon standards76 secured to the framework 36. The creasing and forming rollers 71 areformed of a suitable material so that they will grip the covers as thecartons are moved to the machine. One material which has been found tobe satisfactory consists of soft rubber. However, if longer life isdesired, a knurled metal roller can be provided in its place. The shaft72 has a pulley 78 mounted thereon which is driven by a belt 79. Thebelt 79 is driven by a large pulley 81 mounted upon a shaft 82. Theshaft 82 is driven by a spur gear 83 which is driven by a spur gear 84mounted upon the shaft 43. Each of the rollers is provided with acylindrical surface 86 and a truncated tapered surface 87 adjoining thesurface 86.

As can be seen from FIG. 3, the covers 26 have been lifted approximately90 by the guide strips 61 and enter the guide members 63 and are graspedby the soft rubber rollers 71 which are driven at a slightly greaterspeed as, for example, 10% than the belt 38 and thus have a tendency tograsp the covers 26 and to pull the covers into the guide members 63. Asthey are being advanced into the guide members 63 by the rubber rollers71, the rubber rollers are creasing the cover by engaging the outer sidewall 28. The surface 87 places a crease in the corner of the carton,whereas the surface 86 engages the side wall 28 and forces it below aplane horizontal to the platform 37 by a predetermined angle such as10". Thus, it can be seen that as the cartons are advanced by theconveyor belts, the covers 26 are creased and also formed from thebroken line conformation shown in FIG. 9 to provide the desiredconfiguration shown in solid lines in FIG. 9 for a purpose hereinafterdescribed. The use of the soft rubber rollers causes the cartons to beadvanced and the covers to be creased and formed without danger oftearing the cover or tearing the cover from the bottom section of thecarton.

After the covers have been creased and formed, the cartons advance intowhat can be termed a missing egg detecting station 91. Conventionalmeans is provided for detecting whether an egg is missing and consistsof a photocell detector 92 mounted upon the framework 36 and overlyingthe belt 38 in alignment with each longitudinal row of each carton as itpasses into the station 91. If the photocell detector 92 detects an eggis missing in either of the rows of any of the cartons 17 passingthrough the machine, a signal is supplied to a solenoid 96. The solenoid96 is provided with a plunger 97 which is connected to an arm 98 by alink 99. The arm 98 is connected to a shaft 100 which is mounted in aframe member 101 carried by posts 102 secured to the framework 36. Apair of arms 104 are mounted at spaced points on the shaft 100 and areprovided with a gate member 106 which is normally in a downward positionas shown in FIG. 4. When a carton advances out of the cover creasing andforming station, it is held in a 90 raised position by the gate member106 as shown in FIG. 4.

It will be noted that a gate member 106 is provided only on one side ofeach of the belts 38 for engaging one cover of each of the cartons 17.When the photocell 92 senses that there is an egg missing in either rowof the cartons, the solenoid 96 is energized to cause raising of thegate member 106 and to permit the cover to drop to the dotted lineposition shown in FIG. 4. When the gate 106 is lifted, the stiffness ofthe material which is utilized for the cartons 17 is suflicient to forcethe covers to flop downwardly immediately as soon as the gate member 106is raised.

The other cover of each of the cartons is adapted to be engaged by anL-shaped member 111 secured to the member 101 mounted upon the posts102. Thus, even though there is an egg missing in the row adjacent thecover 26 which is engaged by the member 111, the cover is not dropped.

The cartons are continuously advanced by the conveyor belts 38regardless of whether a cover drops down because an egg is missing. Theyadvance into the carton closing station 116 in which the carton coversare closed. Means is provided in the station 116 for closing the cartoncovers and consists of a pair of rollers 117 and 118 rotatably mountedon members 119 which are secured to standards 121 mounted upon theframework 36. As can be seen particularly from FIGS. 1B and 5, therollers 117 and 118 are inclined at a substantial angle and are adaptedto engage the cover or covers 26 which are still being held in a raisedposition by either the gate member 106 or the angle member 111. Thus,the rollers 117 and 118 move the covers 26 through their first incrementof closing after they have been creased and formed, as shown by thebroken lines in FIG. 5.

Thereafter, the cartons are advanced still further and they engage thesecond set of closing rollers 123 and 124 which are similarly rotatablymounted upon members 119 secured to standards 121 mounted upon theframework 36. The rollers 123 and 124 are inclined at a still furtherangle from the horizontal and close the covers 26 another increment. Bythis time, as can be seen from FIG. 5, the inner walls 28 are beingmoved into engagement with each other. It will also be noted, as can beseen from FIG. 1B, that the hold-down fins 51 terminate short of therollers 123 and 124 so that these fins are not in the way when thecovers are being moved to their closed positions.

After the rollers 123 and 124, the cartons 17 pass under additionalrollers 127 and 128 which are also mounted on members 119. The rollers127 and 128 are inclined at an angle and engage the top covers to pushthe inner walls 28 into the slots 22 of the carton. At the same timethat this is occurring, slide rollers 131 and 132 adjustably positionedon members 136 mounted upon the framework 36 engage the outer side walls27 of the carton and serve to push the covers inwardly to facilitate theentry of the inner walls 28 into the slots 22 of the posts 21. Therollers 131 and 132 also facilitate bringing the covers of the cartoninto their final form. The final closing of the covers is accomplishedby a large closing roller 136 mounted upon a shaft 82 which is driven inthe manner hereinbefore described. The roller 136 is centrally disposedover the conveyor belt and is of such a width that it is adapted toengage both inner edges of both covers 26 of each of the cartons to movethe covers to their final closed position. The cartons have been closedand are ready to be packed or advanced onto other conveyors.

All of the rollers 117, 118, 123, 124, 127, 128 and 136 are preferablyformed of plastic which has rounded corners so that it will not tear orbreak the covers. The rollers are provided with rounded edges so theyalso will not score or tear the covers.

The machine can be operated continuously to continuously crease andreform the carton covers and to close the cartons. In the event that oneof the covers is lying in a flat position as, for example, when the gatemember 106 is raised to indicate that an egg is missing, the operatorattending the machine knows that when a cover is down, an egg must bemissing in the exposed row and if no egg is missing in the exposed row,there must be one missing in the row which is covered. The operator canthen take this carton out of the machine and hand fill the same with anegg and cover the same with the covers by hand.

The creasing and the reforming of the covers forms the covers so thatthe side walls extend in substantially vertical directions and togreatly increase the space within the carton covers which makes thecartons particularly desirable for utilization with large eggs.

By way of example, fins 51 which are utilized in the machine can have athickness such as .0078 of an inch. The inner side wall 28 of the cartoncan have a thickness such as .0055 of an inch so that the combinedthickness of the two covers is slightly greater than the width of theslot so that when both of the inner walls of the two covers are movedinto the slots, they frictionally engage the slots and frictionally holdthe covers in place within the slots in the posts.

Two additional alternative embodiments for the machine are shown inFIGS. 10 and 11 in which the covers can be creased and reformed inpositions other than positions raised from the horizontal. Thus, asshown in FIG. 10, the guides 63 have been mounted on the short posts141. The cartons are adapted to be engaged by a soft roller 142 mountedupon a shaft 143 rotatably mounted in a sleeve 144 secured to theframework 36. The shaft 34 is driven by a pulley 146 which can be drivenfrom a suitable source of power such as an electric motor. In thisembodiment, it can be seen that the cover 26 is creased and formed inthe same manner as in the embodiment hereinbefore described.

In the other embodiment shown in FIG. 11, a different type of roller 151 is provided which has a large inclined surface 151a and a smallcylindrical surface 151b. The roller 151 is driven in a manner similarto the roller 142. However, a bearing block 156 of a differentconfiguration is mounted upon the framework 36. The sleeve 144 ismounted in a block 147 secured to the framework 36. The carton cover iscreased and reformed in much the same manner as hereinbefore described.The principal difference between the arrangement shown in FIGS. 10 and11 and the one hereinbefore described is that the arrangement shown inFIGS. 10 and 11 requires additional width for the machine, particularlywhen two rows of cartons are being closed substantially simultaneously.

It is apparent from the foregoing that there has been provided animproved carton creasing, forming and closing machine which is adaptedfor use with egg cartons of a particular type. The machine can berelatively economically manufactured and can be readily operated byrelatively unskilled labor. The machine can also be readily adjusted.

What is claimed is:

1. A carton creasing, forming and closing machine for use with eggcartons of the type having a bottom section and at least one hingedcover, said cover being formed with inclined side walls at least one ofwhich is hinged to the bottom section, said machine comprising aframework, means mounted on the framework for engaging the bottomsection of the carton and retaining it in a predetermined angularposition, rotatable means engaging the cover for forming the cover sothat the inclined side walls are inclined at a lesser angle and meansfor closing the cover on the bottom section, and conveyor means adaptedto engage the cartons for continuously advancing the cartons through themachine.

2. A machine as in claim 1 together with means for raising the cover ofthe carton prior to the time that it is formed and wherein said meansfor forming the cover of the carton engages the cover of the cartonafter it has been raised.

3. A machine as in claim 1 wherein said means for forming the cartoncover includes a roller having at least a portion of its surfaceinclined with respect to the remainder of the roller.

4. A carton creasing, forming and closing machine for use with eggcartons of the type having a bottom section and at least one hingedcover, said cover being formed with inclined side walls at least one ofwhich is hinged to the bottom section, said machine comprising aframework, means mounted on the framework for engaging the bottomsection of the carton and retaining it in a predetermined angularposition, means engaging the cover for forming the cover so that theinclined side walls are inclined at a lesser angle, means for closingthe cover on 4 the bottom section, and means for sensing when an egg isnot present in a carton and means responsive to said egg sensing meansto cause said cartons to indicate when an egg is missing from a carton.

5. A machine as in claim 4 wherein said means for causing said cartonsto indicate when an egg is missing from a carton includes a gate movablebetween cover retaining and cover releasing positions, and meansactuating said gate in response to said means for sensing.

6. A carton creasing, forming and closing machine for use with eggcartons of the type having a bottom section and at least one hingedcover, said cover being formed with inclined side walls at least one ofwhich is hinged to the bottom section, said machine comprising aframework, means mounted on the framework for engaging the bottomsection of the carton and retaining it in a predetermined angularposition, means engaging the cover for forming the cover so that theinclined side walls are inclined at a lesser angle, said forming meansbeing positioned so that the covers are formed while they are in ahorizontal position, and means for closing the cover on the bottomsection.

7. In a machine for creasing and forming cartons and for closing cartonsof the type which have a bottom section and a pair of covers hinged toopposite sides of the bottom section with each of the covers havinginclined side walls, a framework, conveyor means mounted on theframework for engaging the bottom section and for continuously advancingthe carton, rotatable means engaging the covers for creasing and formingthe covers so that the side walls are inclined at a lesser angle, andmeans for closing the covers on the bottom section.

8. In a machine for creasing and forming cartons and for closing cartonsof the type which have a bottom section, a pair of covers hinged toopposite sides of the bottom section with each of the covers havinginclined side walls, and having posts on the longitudinal center linewith slots in the posts, a framework, conveyor means mounted on theframework for engaging the bottom section and for advancing the carton,means engaging the covers for creasing and forming the covers so thatthe side walls are inclined at a lesser angle, means for closing thecovers on the bottom section, and a hold-down fin positioned so that theslots in said posts travel along the fin, said fin having a length sothat when the covers are moved to a closed position with the side wallsentering the slots, the fin is no longer present in the slots.

9. In a machine for creasing and forming cartons and for closing cartonsof the type which have a bottom section, a pair of covers hinged toopposite sides of the bottom section with each of the covers havinginclined side walls, and posts on the longitudinal center line withslots in the posts, a framework, conveyor means mounted on the frameworkfor engaging the bottom section and for advancing the carton, meansengaging the covers for creasing and forming the covers so that the sidewalls are inclined at a lesser angle, and means for closing the coverson the bottom section including a plurality of rollers engaging thecovers, said rollers being inclined at different angles with respect tothe covers and serving to progressively move the cover towards a closedposition as the carton is advanced.

10. A machine as in claim 9 wherein said means for closing the coversalso includes rollers disposed on opposite sides of the cover andengaging the side 'walls of the covers.

References Cited UNITED STATES PATENTS TRAVIS S. MCGEHEE, PrimaryExaminer US. Cl. X.R. 5 3-376

